3D Printed Protective Devices for Custom Anatomical Fit
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Solution Overview
Problem
There is a long-felt need for a system or method that facilitates the rapid design and manufacturing of customizable protective devices, as existing methods such as hand molding and plaster molding are time-consuming and often fail to provide optimal protection, mobility, and comfort.
Innovation Solution
The system employs computer devices to measure and form models of anatomical features, render and optimize a representation of a customized protective device, and leverage 3D-printing technologies to create the device from the optimized representation, enabling the production of custom, anatomy-fitting protective devices in a matter of days.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hand molding of thermoplastic substrate is used to create customized protective devices, then customization and fit are improved, but the process remains time-consuming and constrained by material and operator skill
Solution Approach 1:
The patent replaces the manual mechanical hand-molding process with an automated 3D printing system. The 3D printer uses digital models derived from patient scans to fabricate protective devices layer by layer, eliminating the need for manual manipulation of thermoplastic substrates by operators. This substitution of mechanical manual processes with automated additive manufacturing achieves both high customization precision and reduced production time.
Solution Approach 2:
The patent changes the fundamental manufacturing parameters from traditional molding (heat, pressure, manual manipulation) to additive manufacturing (layer-by-layer deposition, digital control). By transforming the protective device from a molded subtractive process to a printed additive process, the system achieves superior customization while dramatically reducing the time constraint associated with manual skill-dependent molding.
2Adaptability or versatility
If plaster molding and injection molding are used to create customized protective devices, then material and geometry variation are improved, but the process becomes time-consuming and costly
Solution Approach 1:
The patent replaces the multi-step plaster molding and injection molding mechanical processes with a single 3D printing operation. The system directly fabricates the final protective device from digital models, eliminating the need for creating plaster molds, preparing injection molds, and performing multiple processing steps. This substitution maintains full material and geometry versatility while dramatically reducing production time and cost.
Solution Approach 2:
The patent performs preliminary digital modeling and simulation before actual fabrication. Patient anatomy is scanned and a digital 3D model is created and optimized beforehand, allowing all geometric variations and material selections to be predetermined in the digital domain. This preliminary digital action eliminates the need for time-consuming physical mold making and multiple iterative adjustments during the manufacturing process.
3Productivity
If standard off-the-shelf protective devices are used, then availability and affordability are improved, but fit, coverage, and comfort are compromised
Solution Approach 1:
The patent changes the manufacturing approach from mass production of standardized sizes to on-demand additive manufacturing. By using 3D printing, the system can produce protective devices with exact anatomical measurements for each patient, achieving perfect fit and coverage. The layer-by-layer deposition process allows precise control over geometry and material distribution, ensuring optimal comfort while maintaining affordability through direct digital fabrication without expensive tooling.
4Manufacturing precision
If multiple iterations are required to achieve desired protection, mobility, and comfort, then customization quality is improved, but the entire process from diagnosis to device acquisition extends to several weeks
Solution Approach 1:
The patent replaces the iterative physical trial-and-error process with a single-pass 3D printing fabrication. Digital models are optimized using computer algorithms to ensure optimal protection, mobility, and comfort before printing. The 3D printer then directly fabricates the final device in one continuous process, eliminating the need for multiple physical iterations and reducing the timeline from several weeks to a single production run.
Solution Approach 2:
The patent creates a precise digital copy of the patient's anatomy through 3D scanning, which serves as the foundation for device design. This digital replica allows for virtual testing and optimization of protective device geometry without requiring physical prototypes. The finalized digital model is then directly used to guide the 3D printing process, eliminating the need for multiple physical iterations and significantly reducing the time from diagnosis to device delivery.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for the quick and accurate production of protective devices that provide effective protection while maintaining a normal range of motion and minimizing discomfort, significantly reducing the time from data capture to device delivery.
Implementation Method 1
leverage 3D-printing technologies to create the device from the optimized representation
Data Source
AI summary
A method for generating a representation of a three-dimensional protective device includes accessing a scan of anatomical data of a target and identifying a reference model of a closest size or proportion to a size or proportion of the target. The method further includes creating a boundary of a three-dimensional protective device using the reference model and the scan of anatomical data of the target. Additionally, the method includes generating a representation of a continuous, three-dimensional surface of the three-dimensional protective device that corresponds to the scan of anatomical data and the reference model within the boundary of the three-dimensional protective device.